Course #: 37848 2010© General Motors LLC. All rights reserved. No part of this material may be reproduced in any form or.
Download ReportTranscript Course #: 37848 2010© General Motors LLC. All rights reserved. No part of this material may be reproduced in any form or.
Course #: 37848 2010© General Motors LLC. All rights reserved. No part of this material may be reproduced in any form or by any method (photocopy, microfilm, digital, etc.) without the written permission of General Motors LLC, educational purposes included.
Lockout Energy Control
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Lockout Energy Control
Requirements for Lockout Energy Control
Lockout Energy Control
The purpose of this module is to provide leaders with the summary of the Lockout Energy Control Program as one of the GMs’ risk control programs. The module includes – Awareness of historical issues – Description program requirements – Control measures – Leadership actions
Lockout Energy Control
Lockout is a technique used to prevent the release of hazardous energy, or to prevent the hazardous energy from escaping.
Lockout Energy Control
Hazardous energy may be any energy that could cause harm to a worker such as: Electrical Mechanical (such as pneumatic, hydraulic, springs, parts moved by gravity, spinning flywheels, pressurized systems, etc.)
Lockout Energy Control
Workers are seriously injured or lose their lives because they failed to control hazardous energy while working on, maintaining or repairing machinery and equipment.
Lockout Energy Control
Failure to stop equipment Failure to disconnect from power source Failure to dissipate (bleed, neutralize) residual energy Accidental restarting of equipment Failure to clear work areas before restarting
Lockout Energy Control Plant Location
: Body Systems Paint
Description of Incident
: Two electricians were assigned to replace the shunt trip mechanism on a 1200 amp General Electric Breaker in the Paint Mix Motor Control Center. The Buss Plug Feeding the breaker was locked out in accordance with the posted lockout placard and power at the breaker feed on top of the breaker was checked and verified to be zero.
Lockout Energy Control Plant Location
: Body Systems Paint
Description of Incident
: As one of the team members began work, he laid his screwdriver across two legs at the bottom of the breaker that he assumed were also de-energized.
The handle of the screwdriver rolled off the leg it was resting on causing the metal screwdriver shaft to contact the legs.
There was a flash and two substation breakers tripped.
The team member received a flash burn to his wrist and was temporarily blinded by the flash. Investigation revealed that the breaker had a redundant power feed from an adjacent breaker cabinet.
Lockout Energy Control Plant Location
: Body Systems Paint
Injury Status
: First Degree burn to the right forearm
Contributing Factors and Comments
Lockout placard did not reflect that the breaker had a redundant power feed from an adjacent panel and that both panels needed to be locked out in order to achieve a zero energy state in either breaker.
The team member did not verify zero energy at the bottom of the breaker bar.
Lockout Energy Control GM Occupational Fatalities
65% 35% Lockout related Non-lockout Related
Lockout Related Fatalities
12% 19% 12% 57% Electricians Millrights Machine Repair Persons Other Trades
Lockout Energy Control
Design-In Safety requirements Lockout procedures Monitored Power Systems Training Warnings and placards
Lockout Energy Control
The lockout program consists of other components which must be considered – GM Policy – Laws and regulations – Personnel roles and responsibilities – Procedures (SOPs) – Inspections We will review each of these in the next few slides.
Lockout Energy Control
Lockout is required where employees or contract persons may be exposed to hazardous energy that could cause injury. Exposure means that the employee or contract person is in a position to be injured by released energy.
Lockout Energy Control
Where an employee or contract person is exposed to potential injury from expected machine energy or motion, the exposure must be eliminated. If the exposure cannot be eliminated, the machine will be locked out.
This policy is designed to meet regional regulatory requirements.
Lockout Energy Control
Depending on your location, you may also be subject to additional governmental regulations regarding lockout.
Lockout Energy Control
Who do you need to be concerned about with regard to lockout? There are three defined roles: Affected person Authorized person Competent person
Lockout Energy Control Affected person
A person who performs duties in an area where the lockout energy control procedure is implemented and service or maintenance tasks are performed. An affected person does not service or maintain equipment or machines and is not responsible for implementing the lockout energy control procedure.
Lockout Energy Control
Affected person
Authorized person
A person who performs service or maintenance tasks on machines and equipment. Lockout is used by an authorized person for his/her own protection.
Lockout Energy Control
Affected person Authorized person
Competent person
A management-designated person who has the knowledge and skills to inspect for adherence to Lockout/Hazardous Energy Control Program requirements. The management-designated person must have completed General Motors lockout / energy control training.
Lockout Energy Control
Authorized and Competent Persons must be trained to – Recognize hazardous energy – Identify types of energy – Understand methods and means of isolation and energy control – Identify elements of the Lockout Energy Control Procedure – Have on-the-job familiarization with energy control and isolating devices
Lockout Energy Control
1. Evaluate jobsite for hazardous energy 2. Identify each hazardous energy source 3. Determine whether any hazardous energy found can be eliminated or controlled • • If yes, then eliminate or control the energy If no, then implement lockout procedures 4. Perform action and verify
Lockout Energy Control
Each Lockout control program should include the following: Facility Lockout Procedure Purpose of Procedure Training Requirements Sequence of Lockout Procedure Procedure for Restoring Equipment to Service Lock Removal Procedure
Lockout Energy Control
There are well-established procedures at all GM facilities for performing lockout. These procedures address: De-energizing and locking out equipment Restoring power to equipment Removing another worker’s personal lock
Lockout Energy Control
As a leader, the two most important points for you to remember are: Only persons that are adequately trained and issued a GM personal lock are permitted to enter a hazardous work area Never remove or tamper with another worker’s lock without following the proper procedure
Lockout Energy Control
An inspection must be conducted annually Primary responsibility: management designated employee, such as a general supervisor, supervisor, or other competent employee Inspections will be a certified by a member of management
Lockout Energy Control
Inspections may use a representative random sample that considers all: – Authorized persons – Machines – Processes Inspections must include interviews to assess employee knowledge of policies and procedures – Interviews must be documented
Lockout Energy Control
The supervisor should be notified if: – The machinery or equipment does not have adequate energy control devices for lockout – The machine or equipment must be energized during the maintenance or servicing task and workers may be exposed to a hazard
Lockout Energy Control
An SOP must be created if: – Engineering and Maintenance determine that a hazardous condition identified in an Inadequate Lockout Form cannot be immediately eliminated – The machine or equipment must be energized during the maintenance or servicing task and the maintenance person will be exposed to a hazard.
Lockout Energy Control
An SOP provides specific directions for eliminating exposure and/or controlling an energy hazard
Lockout Energy Control
An SOP provides specific directions for eliminating exposure and/or controlling an energy hazard SOPs can eliminate exposure using: – Modified work methods – Repositioning – Safeguarding devices – PPE
Lockout Energy Control
An SOP provides specific directions for eliminating exposure and/or controlling an energy hazard SOPs can eliminate exposure using: – Modified work methods – Repositioning – Safeguarding devices – PPE Each SOP is specific to the equipment or machine and to the task to be performed
Lockout Energy Control
Each SOP must contain the following information: – Machine/equipment identifier – Date – Written by – Task – Hazard(s) – Purpose – Precautionary safety measures
Lockout Energy Control
Electrical Energy Hydraulic Energy Pneumatic Energy Gravity Stored Mechanical Energy, Including Momentum Special Energy Systems Multiple Energy Systems
Lockout Energy Control
Electrical Energy Hydraulic Energy Pneumatic Energy Gravity Stored Mechanical Energy, Including Momentum Special Energy Systems Multiple Energy Systems
Lockout Energy Control
Cylinder Electrical Energy Hydraulic Energy Pneumatic Energy Gravity Stored Mechanical Energy, Including Momentum Special Energy Systems Multiple Energy Systems
Lockout Energy Control
Electrical Energy Hydraulic Energy Pneumatic Energy Gravity Electrically powered pneumatic valve Stored Mechanical Energy, Including Momentum Special Energy Systems Multiple Energy Systems Pneumatic valve
Lockout Energy Control
Electrical Energy Hydraulic Energy Pneumatic Energy Gravity Stored Mechanical Energy, Including Momentum Special Energy Systems Multiple Energy Systems Point of insertion Pin
Lockout Energy Control
Electrical Energy Hydraulic Energy Pneumatic Energy Robot counterbalance spring Gravity Stored Mechanical Energy, Including Momentum Special Energy Systems Multiple Energy Systems Spindle on a drill press
Lockout Energy Control
Electrical Energy Hydraulic Energy Pneumatic Energy Gravity Stored Mechanical Energy, Including Momentum Special Energy Systems Multiple Energy Systems
Lockout Energy Control
Electrical Energy Hydraulic Energy Pneumatic Energy Gravity Stored Mechanical Energy, Including Momentum Special Energy Systems Multiple Energy Systems
Lockout Energy Control
A lockout device provides protection by preventing the equipment or machine from becoming energized Lockout devices and identification labels must be: – Durable – Standardized – Identifiable – Substantial
Lockout Energy Control
Each GM facility is directed to provide each employee authorized under the GM Lockout Energy Control Program with a common personal lock to be used to lock out energy sources in accordance with the program.
“One person – one lock – one key.”
Lockout Energy Control
Safety locks are to be: Used only by the authorized person Used for lockout purposes only Carried during work hours
Lockout Energy Control
A tag: – Is not a substitute for a lock – Offers no protection – Can be easily removed, overlooked, or defeated An identification tag is to be used only in conjunction with an approved lock
Lockout Energy Control
Scissors Cable or chains Safety blocks Wedges Adjustable safety block Gravity pins
Lockout Energy Control
Placards are designed to assist in identifying: Types of energy that must be controlled Locations of the energy isolating devices Procedural steps for shutting down, isolating, blocking, and securing machines or equipment Procedural steps for the placement, removal, and transfer of lockout devices Requirements for verifying neutralization of energy sources Exposure to special conditions that might affect the control of energy
Lockout Energy Control
All placards must include: Header Graphic Information grid Awareness items
Lockout Energy Control
A designated authorized person performs the step-by-step process of isolation and verification as identified on the placard.
Lockout Energy Control
A designated authorized person performs the step-by-step process of isolation and verification as identified on the placard.
If the procedure is determined complete and correct, the placard is posted along with the accompanying energy source tags or stickers.
Lockout Energy Control
A designated authorized person performs the step-by-step process of isolation and verification as identified on the placard.
If the procedure is determined complete and correct, the placard is posted along with the accompanying energy source tags or stickers.
If it cannot be validated that all energy sources are locked out and verified by the procedure, necessary actions are taken to correct the situation, and the process begins again.
Lockout Energy Control
The GMS Health & Safety Self-assessment Tool enables leaders to accurately measure facility’s health and safety management activities against specific criteria Self-assessment is required annually The Self-assessment tool is available on the Health and Safety web portal. A link is also provided in the Resource section of this presentation.
Lockout Energy Control
Lockout Energy Control Plant follows a documented Lockout Energy Control program.
Procedures must be developed and available for workers prior to work performance.
– The program should be reviewed annually – Workers must be trained
Lockout Energy Control The plant audits the employees whose work involves Lockout/Energy Control annually to verify that they understand proper procedure.
Lockout inspections must include interviews to assess employee knowledge of policies and procedures. Interviews must be documented.
Lockout Energy Control Plant reviews its Lockout/Energy Control inspection process annually.
Inspection will include:: – – – – The required task Specifically-designated energy control procedures Proper use of energy-isolating devices, when required Proper application of locks by each authorized person, when required – Deviations from established plant lockout energy control policy or procedures – Validity of posted lockout placards
Lockout Energy Control The plant audits its Lockout/Energy Control placards annually and updates them as required.
Placards must be validated by an authorized person to determine if the procedure is complete and correct.
Lockout Energy Control All Lockout/Energy Control points are clearly marked.
Lockout identification labels must be: – Durable – Standardized – Identifiable – Substantial
Lockout Energy Control Proper Lockout/Energy Control placards are posted where needed.
Placards must include all required information and be validated
Lockout Energy Control All employees whose work involves Lockout/Energy Control and their direct supervisors are properly trained.
All Authorized and Competent Persons must be trained to recognize hazardous energy and the understand methods required to isolate and control the energy
Lockout Energy Control Only safety locks and other lockout devices that meet the General Motors requirements are used to isolate energy sources.
Each employee is provided a common personal lock to be used to lock out energy sources in accordance with the program –
“One person – one lock – one key.”
Lockout Energy Control Click the button next to the correct answer choice.
A plant must review the inspection audit process once every two years.
Lockout Energy Control The plant must review its Lockout/Energy Control inspection process annually to meet the assessment criteria.
Lockout Energy Control The plant must review its Lockout/Energy Control inspection process annually to meet the assessment criteria.
Lockout Energy Control Click the button next to the correct answer choice.
What are the three (3) defined roles for personnel in lockout implementation?
a) Affected Person, Authorized Person and Competent Person
Lockout Energy Control
The three types of personnel involved in lockout implementation are the Affected Person, Authorized Person and Competent Person.
Lockout Energy Control
The three types of personnel involved in lockout implementation are the Affected Person, Authorized Person and Competent Person.
Lockout Energy Control Click the button next to the correct answer choice.
A Lockout control program should
not
include:
Purpose of the procedure Sequence of the lockout procedure Lockout removal procedure
Lockout Energy Control
A Lockout control program should include the following: Facility Lockout Procedure Purpose of Procedure Training Sequence of Lockout Procedure Procedure for Restoring Equipment to Service Lock Removal Procedure
Lockout Energy Control
A Lockout control program should include the following: Facility Lockout Procedure Purpose of Procedure Training Sequence of Lockout Procedure Procedure for Restoring Equipment to Service Lock Removal Procedure
Lockout Energy Control Click the button next to the correct answer choice.
Which of the following is not a type of energy considered for lockout energy control?
Lockout Energy Control
The types of energy are Electrical Energy Hydraulic Energy Pneumatic Energy Gravity Stored Mechanical Energy, including Momentum Multiple Energy Systems Special Energy Systems
Lockout Energy Control
The types of energy are Electrical Energy Hydraulic Energy Pneumatic Energy Gravity Stored Mechanical Energy, including Momentum Multiple Energy Systems Special Energy Systems
Lockout Energy Control Click the button next to the correct answer choice.
A maintenance worker has determined that a piece of equipment must be energized during a servicing task. Should the worker notify the supervisor?
Lockout Energy Control
The supervisor should be notified if: The machinery or equipment does not have adequate energy control devices for lockout The machine or equipment must be energized during the maintenance or servicing task and workers may be exposed to a hazard
Lockout Energy Control
The supervisor should be notified if: The machinery or equipment does not have adequate energy control devices for lockout The machine or equipment must be energized during the maintenance or servicing task and workers may be exposed to a hazard
Lockout Energy Control
Subject Matter Expert • Global Lockout Resource / SME - Kyle Sullivan [email protected]
Safetypedia • Located on the Health and Safety web portal https://gmweb.gm.com/manufacturing/mfg_ghs/Safetypedia/in dex.htm
Web Resources • GMS Health & Safety Requirements https://gmweb.gm.com/manufacturing/mfg_ghs/Pages/GMSH ealthSafetyRequirements.aspx
Lockout Energy Control
This concludes the Lockout Energy Control Leadership Overview course. Thank you for your participation.
To receive credit for this course: Open mySocrates (not Socrates) Click on the link below for the Global Learning Management System (LMS) to complete an online assessment.
Once inside the LMS, launch the assessment for Course #37848 (GMS Overview Lock Out Energy Control).
Link: Global Learning Management System (LMS)
Lockout Energy Control
Lockout Energy Control
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Requirements for Lockout Energy Control